Conductive paste based on nano-hybrid materials

ABSTRACT

Hybrid particles having improved electrical conductivity and thermal and chemical stabilities are disclosed. The hybrid particles are for use in conductive pastes. The hybrid particles include a nanoparticle selected from a graphene-containing material, a dichalcogenide material, a conducting polymer, or a combination thereof encapsulated in a conducting metal. The hybrid particles include a nanoparticle selected from a graphene-containing material, a dichalcogenide material, or a combination thereof encapsulated in a conducting polymer, and optionally further in a conducting metal. Suitable conducting metals include nickel or silver. Suitable conducting polymers include polyaniline, polypyrrole, or polythiophene. Suitable dichalcogenide materials include MoS 2  or MoSe 2 . The hybrid particles can further include a conducting polymer layer on an outer surface of the conducting metal. Methods of making the hybrid particles are also disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of and priority to U.S. ProvisionalApplication Ser. No. 62/747,944 filed on Oct. 19, 2018, the disclosureof which is expressly incorporated herein by reference in its entirety.

BACKGROUND

Silver paste is highly conductive and generally consists of silverparticles, a thermoplastic resin, and a dispersant. The conventionalsilver paste, however, is very expensive due to the high cost of silverand scarcity of the materials. Pastes containing copper or nickel havebeen developed and show appreciable conductivity but loses stabilityover time. Graphene and silver containing pastes have been found to havehigh conductivity and better stability.

There is a need for conductive pastes comprising materials that are costeffective and have good compatibility, conductivity, stability,adhesion, and corrosion resistance. The materials and methods disclosedherein address these and other needs.

SUMMARY

In accordance with the purposes of the disclosed materials and methods,as embodied and broadly described herein, the disclosed subject matter,in one aspect, relates to hybrid particles having improved electricalconductivity and thermal and chemical stabilities. The disclosed hybridparticles can be used in a conductive paste, a sensor application, forsunlight control, catalytic activity, non-linear optical effect,antibacterial activity, or stretchable electronics applications. In someexamples, the hybrid particles can be used in conductive pastes,preferably as a partial or complete replacement of silver in silverconducting pastes.

In some aspects, the hybrid particles are in the form of core-shellparticles. The hybrid core-shell particles can comprise a nanoparticlecore selected from a graphene-containing material, a dichalcogenidematerial, a conducting polymer, or a combination thereof and a shell atleast partially surrounding the nanoparticle core, wherein the shellcomprises a conducting metal. In other aspects, the hybrid core-shellparticles can comprise a nanoparticle selected from agraphene-containing material, a dichalcogenide material, or acombination thereof encapsulated in a conducting polymer. Suitablegraphene-containing materials include graphene, graphene oxide, carbonnanoparticles including carbon nanotubes, or a combination thereof.Suitable dichalcogenide materials include molybdenum disulphide,molybdenum diselenide, molybdenum ditelluride, tungsten disulphide,tungsten diselenide, tungsten ditelluride, titanium diselenide, titaniumdisulphide, titanium ditelluride, zirconium disulphide, zirconiumdiselenide, zirconium ditelluride, tin disulphide, tin diselenide,tantalum disulphide, tantalum diselenide, vanadium tantalum ditelluride,or a combination thereof. Suitable conducting metals include nickel,silver, or combinations thereof. Suitable conducting polymers includepolyaniline, polypyrrole, polythiophene, poly(ortho-anisidine),poly(methyl aniline), poly(o-ethoxyaniline), poly (o-toluidine) (POT),poly (ethoxy-aniline), substituted polyaniline, substituted polypyrrole,polyindole, polyethylenedioxythiophene (PEDOT), polycarbazole,substituted polycarbazole, polyaniline-polypyrrole copolymers,polyaniline-polythiophene copolymers, blends thereof, or copolymersthereof.

In certain embodiments, the nanoparticle core is selected from agraphene-containing material or a dichalcogenide material. Accordingly,the hybrid core-shell particles can include a nanoparticle core selectedfrom a graphene-containing material or a dichalcogenide material and ashell comprising a conducting metal. In these examples, the hybridcore-shell particles can further include a conducting polymer layer onan outer surface of the shell.

Representative examples of hybrid core-shell particles disclosed hereininclude graphene oxide-nickel particles, graphene-nickel particles,molybdenum disulphide-nickel particles, graphene oxide-silver particles,graphene-silver particles, molybdenum disulphide-silver particles,graphene oxide-nickel-conducting polymer particles,graphene-nickel-conducting polymer particles, molybdenumdisulphide-nickel-conducting polymer particles, grapheneoxide-silver-conducting polymer particles, graphene-silver-conductingpolymer particles, and molybdenum disulphide-silver-conducting polymerparticles.

In the hybrid core-shell particles, the core can comprise from 20-80 wt%, from 30-70 wt %, or from 30-60 wt %, of the particle; and/or theshell comprises from 20-80 wt %, from 30-70 wt %, or from 30-60 wt %, ofthe particle. The particles can have an average particle size of from 50nm to 10 microns, from 100 nm to 5 microns, or from 100 nm to 2 microns.

As described herein, the hybrid core-shell particles can be used inconducting pastes. The hybrid core-shell particles can be present in anamount of 50 wt % or greater, from 50-90 wt %, or from 70-85 wt %, ofthe composition. In addition to the hybrid core-shell particles, theconducting pastes can further include a dispersant or surfactant (forexample, propylene carbonate, polyoxyethylene-p-(1,1,3,3-tetramethylbutyl) phenyl ethers, X-triton, n-methylpyrrolidinone, ionic liquid, diethylene glycol monobutyl ether,polyvinyl alcohol, and such the like), an adhesive material, or acombination thereof. Suitable adhesive materials include an epoxy resin,a vinyl ester resin, a polystyrene resin, an acrylic resin, a polyamideresin, a polyamide-amine resin, a carboxyl group-containing resin, or acombination thereof. The adhesive can be present in an amount of 50 wt %or less, from 10-50 wt %, or from 15-30 wt %, of the composition.

As described herein, the conductive pastes described herein provides acost effective paste with good compatibility, conductivity, stability,adhesion, and corrosion resistance compared to conventional silverpastes. In some embodiments, the conductive pastes disclosed hereincomprise less than 10 wt % of silver, or is substantially free ofsilver.

Methods of making the hybrid core-shell particles are also disclosed.The method can include depositing a conducting metal and/or a conductingpolymer on a surface of the nanoparticle. Deposition of the conductingmetal or conducting polymer can be by electrochemical deposition or byother methods known to those skilled in the art.

Additional advantages will be set forth in part in the description thatfollows, and in part will be obvious from the description, or may belearned by practice of the aspects described below. The advantagesdescribed below will be realized and attained by means of the elementsand combinations particularly pointed out in the appended claims. It isto be understood that both the foregoing general description and thefollowing detailed description are exemplary and explanatory only andare not restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows schematic drawings showing the structure of polyaniline(PANI), graphene oxide, and molybdenum disulfide (MoS₂) nanomaterialscoated with nickel or silver.

FIG. 2 shows schematic drawings showing the structure of a conductingpolymer coating on Ni-coated graphene or Ni-coated MoS₂ nanomaterials.

FIG. 3 shows the structure of nanomaterials used in the presentdisclosure.

FIG. 4 shows polystyrene sulfonate (PSS) treatment of the nanomaterials,graphene oxide and MoS₂.

DETAILED DESCRIPTION

The materials, compounds, compositions, and methods described herein maybe understood more readily by reference to the following detaileddescription of specific aspects of the disclosed subject matter, theFigures, and the Examples included therein.

Before the present materials, compounds, compositions, and methods aredisclosed and described, it is to be understood that the aspectsdescribed below are not limited to specific synthetic methods orspecific reagents, as such may, of course, vary. It is also to beunderstood that the terminology used herein is for the purpose ofdescribing particular aspects only and is not intended to be limiting.

Also, throughout this specification, various publications arereferenced. The disclosures of these publications in their entiretiesare hereby incorporated by reference into this application in order tomore fully describe the state of the art to which the disclosed matterpertains. The references disclosed are also individually andspecifically incorporated by reference herein for the material containedin them that is discussed in the sentence in which the reference isrelied upon.

General Definitions

In this specification and in the claims that follow, reference will bemade to a number of terms, which shall be defined to have the followingmeanings:

Throughout the specification and claims the word “comprise” and otherforms of the word, such as “comprising” and “comprises,” means includingbut not limited to, and is not intended to exclude, for example, otheradditives, components, integers, or steps.

As used in the description and the appended claims, the singular forms“a,” “an,” and “the” include plural referents unless the context clearlydictates otherwise. Thus, for example, reference to “a polymer” includesmixtures of two or more such polymers, and the like.

“Optional” or “optionally” means that the subsequently described eventor circumstance can or cannot occur, and that the description includesinstances where the event or circumstance occurs and instances where itdoes not.

Notwithstanding that the numerical ranges and parameters setting forththe broad scope of the disclosure are approximations, the numericalvalues set forth in the specific examples are reported as precisely aspossible. Any numerical value, however, inherently contain certainerrors necessarily resulting from the standard deviation found in theirrespective testing measurements. Furthermore, when numerical ranges ofvarying scope are set forth herein, it is contemplated that anycombination of these values inclusive of the recited values may be used.Further, ranges can be expressed herein as from “about” one particularvalue, and/or to “about” another particular value. When such a range isexpressed, another aspect includes from the one particular value and/orto the other particular value. Similarly, when values are expressed asapproximations, by use of the antecedent “about,” it will be understoodthat the particular value forms another aspect. It will be furtherunderstood that the endpoints of each of the ranges are significant bothin relation to the other endpoint, and independently of the otherendpoint. Unless stated otherwise, the term “about” means within 5%(e.g., within 2% or 1%) of the particular value modified by the term“about.”

As used herein, the term “composition” is intended to encompass aproduct comprising the specified ingredients in the specified amounts,as well as any product which results, directly or indirectly, fromcombination of the specified ingredients in the specified amounts.

References in the specification and concluding claims to parts by weightof a particular element or component in a composition denotes the weightrelationship between the element or component and any other elements orcomponents in the composition or article for which a part by weight isexpressed. Thus, in a mixture containing 2 parts by weight of componentX and 5 parts by weight component Y, X and Y are present at a weightratio of 2:5 and are present in such ratio regardless of whetheradditional components are contained in the mixture.

Compositions

Hybrid particles having enhanced electrical conductivity, corrosionresistance, and thermal and chemical stabilities are disclosed herein.The term “hybrid” as used herein refers to a particle comprising atleast two components. Suitable components include two or more materialsselected from a nanoparticle, a conducting metal, or a conductingpolymer as described herein. Compositions containing the hybridparticles are also disclosed. The hybrid particles can be used as areplacement for silver in conventional silver conducting pastes.

In some aspects, the hybrid particles include a nanoparticleencapsulated within a conducting metal. In other aspects, the hybridparticles include a nanoparticle encapsulated within a conductingpolymer. The term “encapsulated” as used herein refers to thenanoparticle (core) being partially or completely surrounded by theconducting metal or conducting polymer (shell) in which it isencapsulated. The nanoparticle preferably includes a 2-dimensional (2D)layered structure and is also a conducting material. The term“nanoparticle” as used herein refers to any structure whose primaryaverage particle size is less than 1 micron, preferably less than 500nm, such as less than 350 nm in one dimension. For example, ananoparticles can comprise a nanowire, nanotube, nanorod, sphericalnanoparticle, nanopore, and the like, or combinations thereof. As such,the term nanoparticle can comprise, for example, a nanowire, nanotube,nanorod, spherical nanoparticle, nanopore, or a combination thereof. Thenanoparticle can be a 2D (such as a flake) or a 3D (such as a sphere)particle. Particle size can be measured by Dynamic Light Scattering(DLS) and Transmission Electron Microscopy (TEM). In some examples, thenanoparticles can have an average particle size of 0.5 nm to less than1000 nm. For example, the nanoparticles can have an average particlesize of from 0.5 nm to 500 nm, from 0.5 nm to 300 nm, from 0.5 nm to 200nm, from 0.5 nm to 100 nm, from 0.5 nm to 75 nm, from 0.5 nm to 50 nm,from 0.5 nm to 40 nm, from 0.5 nm to 30 nm, from 0.5 nm to 15 nm, from0.5 nm to 10 nm, from 0.5 nm to 5 nm, 1 nm to 500 nm, from 1 nm to 300nm, from 1 nm to 200 nm, from 1 nm to 50 nm, from 1 nm to 40 nm, from 1nm to 30 nm, from 1 nm to 15 nm, from 1 nm to 10 nm, from 1 nm to 5 nm,2 nm to 500 nm, from 2 nm to 300 nm, from 2 nm to 200 nm, from 2 nm to50 nm, from 2 nm to 40 nm, from 2 nm to 30 nm, from 2 nm to 15 nm, from2 nm to 10 nm, or from 2 nm to 5 nm.

In preferred examples, the nanoparticle can include agraphene-containing material, a dichalcogenide material, or a conductingpolymer. Graphene is a two-dimensional hexagonal lattice honeycombstructure and includes sp² carbon atoms. Graphene has excellentelectrical conductivity and mechanical properties. Graphene also hasexcellent chemical and thermal properties, high electrical conductivity,high surface area, and high mechanical strength properties. Thegraphene-containing material can include graphene nanoparticles,graphene oxide nanoparticles, or a combination thereof.

The graphene nanoparticles can include both single-atom-thick planarsheets of sp² hybridized carbon as well as materials comprising two ormore stacked layers of such sheets. The planar sheets of sp² hybridizedcarbon may form an essentially hexagonal lattice. Similarly, thegraphene oxide nanoparticles can include single-atom thick planar sheetsof graphite oxide as well as materials comprising two or more stackedlayers of such sheets. In some embodiments, the graphene nanoparticlesor the graphene oxide nanoparticles can comprise single sheets, twosheets, three sheets, four sheets, five sheets, six sheets, sevensheets, eight sheets, nine sheets, and/or ten sheets of the single-atomthick planar sheet. The graphene oxide nanoparticles can be derived fromoxidizing carbonaceous materials having small (nanometer scale) graphitecrystalline domains. Examples of carbonaceous materials includemesoporous carbons, graphitized mesoporous carbons, carbon black,conductive carbon black, activated carbon, black carbon (soot), and thelike.

In further examples, the nanoparticle can include carbon nanoparticlesincluding carbon nanotubes. Examples of carbon nanotubes includesingle-walled carbon nanotubes (SWCNTs) and multi-walled carbonnanotubes (MWCNTs), and combinations thereof.

As described herein, the nanoparticle can include a dichalcogenidematerial. U.S. Patent Publication No. 2003/0056819 disclosesconventional dichalcogenide materials having a two-dimensional layeredstructure. In some embodiments, the dichalcogenide materials can berepresented by Formula A_(x)BC_(2-y) where 0≤x≤2 and 0≤y<1, wherein Acomprises at least one element selected from the group consisting of Li,Na, K, Rb, Cs, Mg, Ca, Sr, Ba, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Zr,Nb, Mo, Ru, Rh, Pd, Ag, Cd, Hf, Ta, W, Re, Ir, Pt, Au, Sc, Y, and a rareearth element, B comprises at least one element selected from the groupconsisting of Ti, V, Cr, Zr, Nb, Mo, Hf, Ta, W, Ir, and Sn, and Ccomprises one of S, Se, and Te. In some examples, the dichalcogenidematerial can include molybdenum disulphide, molybdenum diselenide,molybdenum ditelluride, tungsten disulphide, tungsten diselenide,tungsten ditelluride, titanium diselenide, titanium disulphide, titaniumditelluride, zirconium disulphide, zirconium diselenide, zirconiumditelluride, tin disulphide, tin diselenide, tantalum disulphide,tantalum diselenide, vanadium tantalum ditelluride, or a combinationthereof.

As further described herein, the nanoparticle can include a conductingpolymer. The conducting polymer can include a conjugated polymer whoseelectrical and optical properties can be controllably varied. Through achemical “doping” process, it is possible to systematically vary theelectrical conductivity of these materials from the insulating state tothe conducting state. Representative conducting polymers can includepolyacetylene (for example, trans-polyacetylene, cis-type polyacetylene,polydiacetylene), polyaniline, polypyrrole (for example, polypyrrole,poly-3-methylpyrrole and poly-3-octyl pyrrole), polythiophene (forexample, polythiophene, poly(3-alkylthiophene),poly(3-thiophene-$-ethane sulfonic acid, polyalkylene dioxythiophene(such as polyethylenedioxythiophene), and complexes thereof withpolystyrene sulfonate), poly(phenylene) (for example, poly(p-phenylene),poly(m-phenylene), poly(phenylene sulfide), andpoly(phenylenevinylene)), poly(ortho-anisidine), poly (o-toluidine)(POT), polyindole, polycarbazole, substituted polyanilines (for example,poly(methyl aniline), poly(methoxy aniline), and poly(ethoxy aniline)),substituted polypyrrole, substituted polycarbazole,polyaniline-polypyrrole copolymers, polyaniline-polythiophenecopolymers, poly(vinyl sulfide) (for example, poly(p-phenylene sulfide)and poly(thienylene vinylene), blends thereof, or copolymers thereof.

Conducting metals are known in the art and can be selected from gold,silver, copper, platinum, palladium, nickel, aluminum, or an alloyconsisting of two or more metals. Preferably, the conducting metalincludes silver or nickel. In some examples, the conducting metal doesnot include silver.

The hybrid particles disclosed herein can have a core-shell structure.

The term “core-shell” as used herein refers to particles comprising acore material (for example a nanoparticle selected from agraphene-containing nanoparticle, a dichalcogenide material, or aconducting polymer) and shell material (for example a conductingmaterial selected from a conducting metal, a conducting polymer, or acombination thereof). In some embodiments, the shell material caninclude one or more layers. For example, the shell material can includea layer comprising the conducting metal only, a layer comprising theconducting polymer only, or an inner shell layer comprising theconducting metal and an outer shell layer comprising the conductingpolymer.

In some examples, the hybrid core-shell particles can include ananoparticle core comprising a graphene-containing nanoparticle, adichalcogenide material, or a conducting polymer and a shell comprisinga conducting metal. In other examples, the hybrid core-shell particlescan include a nanoparticle core comprising a graphene-containingnanoparticle, a dichalcogenide material, an inner shell layer comprisinga conducting metal, and an outer shell layer comprising a conductingpolymer. Without wishing to be bound by theory, the conducting polymerin the outer shell facilitates dispersion of the particles, therebyallowing the particles to be easily and well dispersed in a binder, suchas in an epoxy resin. The conducting polymer also allows the particlesto be easily applied to surfaces and provides corrosion resistance incompositions comprising the same.

In the hybrid core-shell particles, the core can comprise 20% by weightor greater of the particle (e.g., 20% by weight or greater, 25% byweight or greater, 30% by weight or greater, 35% by weight or greater,40% by weight or greater, 45% by weight or greater, 50% by weight orgreater, 55% by weight or greater, 60% by weight or greater, 65% byweight or greater, 70% by weight or greater, 75% by weight or greater,80% by weight or greater, or 85% by weight or greater, by weight of theparticle.) In some embodiments of the hybrid core-shell particles, thecore can comprise 80% by weight or less of the particle (e.g., 80% byweight or less, 75% by weight or less, 70% by weight or less, 65% byweight or less, 60% by weight or less, 55% by weight or less, 50% byweight or less, 45% by weight or less, 40% by weight or less, 35% byweight or less, 30% by weight or less, 25% by weight or less, 20% byweight or less, or 15% by weight or less, by weight of the particle.) Insome embodiments of the hybrid core-shell particles, the core cancomprise from 10-90 wt %, of the particle (e.g., from 20-90 wt %, from20-85 wt %, from 20-80 wt %, from 30-85 wt %, from 30-80 wt %, from30-75 wt %, from 30-70 wt %, from 20-60 wt %, from 30-60 wt %, from30-50 wt %, from 20-50 wt %, by weight of the particle.)

In the hybrid core-shell particles, the shell can comprise 20% by weightor greater of the particle (e.g., 20% by weight or greater, 25% byweight or greater, 30% by weight or greater, 35% by weight or greater,40% by weight or greater, 45% by weight or greater, 50% by weight orgreater, 55% by weight or greater, 60% by weight or greater, 65% byweight or greater, 70% by weight or greater, 75% by weight or greater,80% by weight or greater, or 85% by weight or greater, by weight of theparticle.) In some embodiments of the hybrid core-shell particles, theshell can comprise 80% by weight or less of the particle (e.g., 80% byweight or less, 75% by weight or less, 70% by weight or less, 65% byweight or less, 60% by weight or less, 55% by weight or less, 50% byweight or less, 45% by weight or less, 40% by weight or less, 35% byweight or less, 30% by weight or less, 25% by weight or less, 20% byweight or less, or 15% by weight or less, by weight of the particle.) Insome embodiments of the hybrid core-shell particles, the shell cancomprise from 10-90 wt %, of the particle (e.g., from 20-90 wt %, from20-85 wt %, from 20-80 wt %, from 30-85 wt %, from 30-80 wt %, from30-75 wt %, from 30-70 wt %, from 20-60 wt %, from 30-60 wt %, from30-50 wt %, from 20-50 wt %, by weight of the particle.)

Representative examples of the hybrid core-shell particles disclosedherein can include graphene oxide (core)-nickel (shell) particles,graphene (core)-nickel (shell) particles, molybdenum disulphide(core)-nickel (shell) particles, graphene oxide (core)-silver (shell)particles, graphene (core)-silver (shell) particles, molybdenumdisulphide (core)-silver (shell) particles, graphene oxide (core)-nickel(inner shell)-conducting polymer (outer shell) particles, graphene(core)-nickel (inner shell)-conducting polymer (outer shell) particles,molybdenum disulphide (core)-nickel (inner shell)-conducting polymer(outer shell) particles, graphene oxide (core)-silver (innershell)-conducting polymer (outer shell) particles, graphene(core)-silver (inner shell)-conducting polymer (outer shell) particles,or molybdenum disulphide (core)-silver (inner shell)-conducting polymer(outer shell) particles.

The hybrid core-shell particles can be sized as nanoparticles ormicroparticles. In some examples, the hybrid core-shell particles canhave an average particle size of 50 nm or greater, 70 nm or greater, 80nm or greater, 100 nm or greater, 150 nm or greater, 200 nm or greater,500 nm or greater, 750 nm or greater, 1 micron or greater, 2 microns orgreater, 3 microns or greater, or 5 microns or greater. In someexamples, the hybrid core-shell particles can have an average particlesize of 10 microns or less, 9 microns or less, 8 microns or less, 7microns or less, 6 microns or less, 5 microns or less, 4 microns orless, 3 microns or less, 2 microns or less, 1 micron or less, 900 nm orless, 800 nm or less, 700 nm or less, 600 nm or less, 500 nm or less,400 nm or less, 300 nm or less, 200 nm or less, or 100 nm or less. Forexample, the hybrid core-shell particles can have an average particlesize of from 50 nm to 10 microns, from 50 nm to 9 microns, from 50 nm to8 microns, from 50 nm to 6 microns, from 50 nm to 5 microns, from 50 nmto 4 microns, from 50 nm to 3 microns, from 50 nm to 2 microns, from 50nm to 1 micron, from 100 nm to 10 microns, from 100 nm to 9 microns,from 100 nm to 8 microns, from 100 nm to 6 microns, from 100 nm to 5microns, from 100 nm to 4 microns, from 100 nm to 3 microns, from 100 nmto 2 microns, from 100 nm to 1 micron, from 200 nm to 10 microns, from200 nm to 9 microns, from 200 nm to 8 microns, from 200 nm to 6 microns,from 200 nm to 5 microns, from 200 nm to 4 microns, from 200 nm to 3microns, from 200 nm to 2 microns, from 200 nm to 1 micron, from 500 nmto 10 microns, from 500 nm to 9 microns, from 500 nm to 8 microns, from500 nm to 6 microns, from 500 nm to 5 microns, from 500 nm to 4 microns,from 500 nm to 3 microns, from 500 nm to 2 microns, from 500 nm to 1micron, from 1 micron to 10 microns, from 2 micron to 10 microns, from 4micron to 10 microns, from 5 micron to 10 microns, from 1 micron to 8microns, from 2 microns to 8 microns, or from 2 microns to 5 microns.

Compositions comprising the hybrid particles are also disclosed herein.For example, composition comprising the hybrid core-shell particles canbe provided in a conductive paste, a sensor application, for sunlightcontrol, catalytic activity, non-linear optical effect, antibacterialactivity, or stretchable electronics applications.

In the compositions provided herein, the hybrid core-shell particles canbe present in an amount of 25% by weight or greater of the compositions(e.g., 30% by weight or greater, 35% by weight or greater, 40% by weightor greater, 45% by weight or greater, 50% by weight or greater, 55% byweight or greater, 60% by weight or greater, 65% by weight or greater,70% by weight or greater, 75% by weight or greater, 80% by weight orgreater, 85% by weight or greater, or 90% by weight or greater, byweight of the composition.) In some embodiments, the hybrid core-shellparticles can be present in an amount of 90% by weight or less of thecomposition (e.g., 85% by weight or less, 80% by weight or less, 75% byweight or less, 70% by weight or less, 65% by weight or less, 60% byweight or less, 55% by weight or less, 50% by weight or less, 45% byweight or less, 40% by weight or less, 35% by weight or less, 30% byweight or less, 25% by weight or less, or 20% by weight or less, byweight of the composition.) In some embodiments, the hybrid core-shellparticles can be present in an amount of from 20-90 wt %, of thecomposition (e.g., from 20-85 wt %, from 30-85 wt %, from 40-85 wt %,from 40-75 wt %, from 50-90 wt %, from 50-85 wt %, from 50-80 wt %, from60-75 wt %, from 70-90 wt %, or from 70-85 wt %, by weight of thecomposition.)

In some examples, the compositions can be in the form of a conductivepastes. In addition to the hybrid particles disclosed herein, theconductive pastes can further comprise a dispersant or surfactant, anadhesive material, or a combination thereof. Suitabledispersants/surfactants include propylene carbonate, polyoxyethylene-p-(1,1,3,3-tetramethylbutyl) phenyl ethers, X-triton, n-methylpyrrolidinone, ionic liquid, diethylene glycol monobutyl ether,polyvinyl alcohol, and such the like. Suitable adhesive materialsinclude an epoxy resin, a vinyl ester resin, a polystyrene resin, anacrylic resin, a polyamide resin, a polyamide-amine resin, a carboxylgroup-containing resin, or a combination thereof.

In the compositions provided herein, the adhesive can be present in anamount of 50% by weight or less of the composition (e.g., 45% by weightor less, 40% by weight or less, 35% by weight or less, 30% by weight orless, 25% by weight or less, 20% by weight or less, 15% by weight orless, or 10% by weight or less, by weight of the composition). In someembodiments, the adhesive can be present in an amount of 5% by weight orgreater of the compositions (e.g., 10% by weight or greater, 15% byweight or greater, 18% by weight or greater, 20% by weight or greater,22% by weight or greater, 25% by weight or greater, 28% by weight orgreater, 30% by weight or greater, 35% by weight or greater, 40% byweight or greater, 45% by weight or greater, or 50% by weight orgreater, by weight of the composition.) In some embodiments, theadhesive can be present in an amount of from 10-50 wt %, of thecomposition (e.g., from 10-40 wt %, from 10-30 wt %, from 15-50 wt %,from 15-45 wt %, from 15-40 wt %, from 15-35 wt %, from 15-30 wt %, from20-45 wt %, from 20-35 wt %, or from 20-30 wt %, by weight of thecomposition).

As described herein, the hybrid particles can be used for example inconductive pastes for partial or complete replacement of silver insilver conducting pastes. The conductive pastes disclosed herein cancomprise less than 20% by weight silver (e.g., less than 18% by weight,less than 15% by weight, less than 14% by weight, less than 13% byweight, less than 12% by weight, less than 10% by weight, less than 9%by weight, less than 8% by weight, less than 7% by weight, less than 6%by weight, less than 5% by weight, less than 4% by weight, less than 3%by weight, less than 2% by weight, or less than 1% by weight, of thecomposition). In some examples, the conductive paste is substantiallyfree of silver.

The compositions exhibit high electrical resistivity, and high thermaland chemical stabilities at room temperature. For example, thecompositions described herein can exhibit an electrical resistivity ofat least 1×10⁻⁵ ohm·cm (for example, greater than 1×10⁻⁵ ohm·cm, greaterthan 2×10⁻⁵ ohm·cm, or greater than 3×10⁻⁵ ohm·cm). In some examples,the compositions described herein can exhibit a thermal conductivity ofat least 8 W/mK (for example, greater than 8 W/mK, greater than 9 W/mK,or greater than 10 W/mK).

Methods

Methods of making and using the hybrid particles are also disclosedherein. The method of making the hybrid particles can include depositinga conducting metal on a surface of a nanoparticle. As described herein,the nanoparticle can include a graphene-containing material, adichalcogenide material, a conducting polymer, or a combination thereof.In embodiments where the nanoparticle includes a graphene-containingmaterial or a dichalcogenide material, the method disclosed herein canfurther comprise depositing a conducting polymer on an outer surface ofthe conducting metal.

The graphene-containing material, dichalcogenide material, and/orconducting polymer can be commercially obtained or synthesized. Methodsfor preparing the dichalcogenide material can comprise a hydrothermalprocess that includes varying the amount of solvent. In specificexamples, a salt of A in the Formula A_(x)BC_(2-y) (such as sodiummolybdate) can be mixed with a sulfur-, selenium-, ortellurium-containing compound (such as thioacetamide) in the solventwater. The resulting solution can be heated above at 100° C. or above150° C. for a period of time (such as at 200° C. for 12 hrs) to obtainthe dichalcogenide material, the dichalcogenide material can be purifiedby centrifugation. In another specific examples, a salt of A in theFormula A_(x)BC_(2-y) (such as sodium molybdate) can be mixed with asulfur-, selenium-, or tellurium-containing compound (such asthioacetamide) in a solvent mixture comprising water and ethyleneglycol. The solvent mixture can comprise water and ethylene glycol in anamount of from 1:5 to 5:1 by volume, from 1:2 to 2:1 by volume, or from1:2 to 1:1 by volume. The resulting solution can be heated above at 100°C. or above 150° C. for a period of time (such as at 200° C. for 24 hrs)to obtain the dichalcogenide material, the dichalcogenide material canbe purified by centrifugation.

Depositing the conducting metal or conducting polymer can be byelectrochemical deposition or by any other method known to those skilledin the art. Suitable set-up for electrochemical deposition can includecell in which a container made of steel acts as an anode electrode. Apotential can be applied above the redox potential of the conductingmetal (for example, NiCl₂ or AgNO₃ can be used to deposit nickel andsilver, respectively) or the conducting monomer (for example aniline canbe used to deposit polyaniline). During electrolysis, the solution canbe stirred after each 1 to 2 minutes. The time period for deposition canbe optimized with scanning electron microscopy (SEM) and/or conductivitymeasurements of the deposited particle. The hybrid particles (such asPANI/Ni, MoS₂/Ni/PANI, GO/Ni/PANI. MoS₂/Ag, GO/Ag) can be characterizedusing scanning electron microscopy, X-ray diffraction andenergy-dispersive (ED) analysis.

In some embodiments, the conducting polymer can be deposited by chemicalsynthesis. For example, the method can include dispersing thenanoparticle (for example graphene oxide or MoS₂) in a polyanion such asa sodium salt of polystyrene sulfonate (PSS). The polyanion allows eachparticle to be functionalize which aids coating of the conductingpolymer. The MoS₂/PSS and graphene oxide/PSS particle structures armshown in FIG. 4 . The MoS₂/PSS and graphene oxide/PSS particles can bedispersed in dodecyl benzene sulfonic acid. A conducting polymer such aspolyaniline can be polymerized over the treated nanoparticles.

The hybrid particles can be used in conductive pastes. In some examples,the hybrid particles can be used as a partial or complete replacement ofsilver in silver conducting pastes.

EXAMPLES

The following examples are set forth below to illustrate the methods andresults according to the disclosed subject matter. These examples arenot intended to be inclusive of all aspects of the subject matterdisclosed herein, but rather to illustrate representative methods,compositions, and results. These examples are not intended to excludeequivalents and variations of the present invention, which are apparentto one skilled in the art.

Efforts have been made to ensure accuracy with respect to numbers (e.g.,amounts, temperature, etc.) but some errors and deviations should beaccounted for. Unless indicated otherwise, parts are parts by weight,temperature is in ° C. or is at ambient temperature, and pressure is ator near atmospheric. There are numerous variations and combinations ofreaction conditions, e.g., component concentrations, temperatures,pressures, and other reaction ranges and conditions that can be used tooptimize the product purity and yield obtained from the describedprocess. Only reasonable and routine experimentation will be required tooptimize such process conditions.

Example 1: Conductive Paste Based on Nano-Hybrid Materials

Introduction: This example provides affordable, durable, electricallyconductive coatings and material solution for silver paint replacement.The conductive materials include a conducting-2D-polymer materials(graphene or MoS₂) based solution. A hybrid core structure of thegraphene-containing material and molybdenum disulfide (MoS₂) wassynthesized by coating with nickel and/or a conducting polymer. FIGS. 1and 2 show the structure of a conducting polymer, graphene oxide (GO),and MoS₂ nanomaterial coated with nickel or silver. The nickel or silvercoating of MoS₂ or graphene GO can be coated over with a conductingpolymer (such as polypyrrole, polythiophene or polyaniline) to providecorrosion resistive highly conducting paste.

The hybrid materials can be exploited for fabrication of hybrid pastes.In particular, the synthesized composites of polymers and nanomaterialshave shown enhanced conductivity, corrosion and thermal properties. Thegraphene has been found to contain high electrical conductivity as wellas intrinsic thermal conductivity. For example, the graphene-polyanilineshowed conductivity with very high specific capacitance of 300-500 F g⁻¹at a current density of 0.1 A g⁻¹. Further, the hybrid coating materialsexemplified have shown stability between −65° F. to 250° F. Thecommercial applications of the developed material can be exploited inairframes, conductive pastes, and silver paints.

General Procedure: Hybrid nanomaterials were synthesized and samplesprepared for characterizations. The surface morphology, electricalconductivity, electrochemical and corrosion properties of the sampleswere then made. The hybrid particles were then combined with athermoplastic resin and a dispersant to create paste. Electrochemicalcorrosion measurements of steel with and without the paste were made.The charge transfer resistance of paste samples was then studied throughimpedance spectroscopy to understand the corrosion inhibition behavior.A model was made based on the experimental results to understand theconductivity of the samples.

Synthesis nanomaterial, functionalization and characterization: Threenanomaterials (polyaniline, graphene and MoS₂) were selected as shownFIG. 3 . The graphene was procured commercially, MoS₂ was procuredcommercially or synthesized as described herein, and the polyanilinenanoparticle were synthesized.

Synthesis of MoS₂ particles: The MoS₂ particles were prepared by varyingthe water and water and ethylene glycol concentration using ahydrothermal process. In a first process, sodium molybdate(Na₂MoO₄·2H₂O; 50 mg) was added with thioacetamide (C₂H₅NS; 100 mg) to100 ml of water. The resulting solution was heated at 200° C. for 12 hrsin an autoclave (Teflon lining in stainless steel based cylinder).Nanoparticles of MoS₂ was obtained after cleaning by a centrifugationprocess.

In a process, MoS₂ nanoparticles were formed by using ethylene glycol asthe primary solvent. A solution was prepared by mixing Na₂MoO₄·2H₂O (50mg) and 40 mg of C₂H₅NS in 40 ml of water and subsequently with 60 ml ofethylene glycol. The solution was heated to 200° C. for 24 hrs. MoS² wascollected using water washing and a centrifugation process.

Synthesis of polyaniline nanoparticles: The polyaniline was made in thepresence of a surfactant following the earlier work of Ram et al.Briefly, the monomer aniline, dodecylbenzosulfonic acid, and ammoniumpersulfate (APS) were mixed at suitable proportion using hydrochloricacid. The polyaniline nanoparticle reaction was left to stand for 24hrs. The nanoparticles formed were cleaned using a centrifuge and waterand later, treated with 1 M HCl to maintain the conductivity.

Chemical synthesis of conducting polymer over graphene oxide and MoS₂.The nanomaterial (graphene oxide and MoS₂) were dispersed in a polyanionsuch as the sodium salt of polystyrene sulfonate (PSS) so that eachparticle was functionalized which allows the conducting polymer to becoated. The MoS₂/PSS and graphene oxide/PSS particles structures areshown in FIG. 4 . The MoS₂/PSS and graphene oxide/PSS particles werethen dispersed in dodecyl benzene sulfonic acid. Polyaniline waspolymerized over the graphene oxide and MoS₂ nanoparticles.

Electrochemical deposition of metal or conducting polymer over ofnanomaterial using electrochemical technique: A specially designedelectrochemical set-up was used in which the container was made of steeland acts as an anode electrode. A potential was applied above the redoxpotential of the monomer (aniline) or metal (Ni or Ag). NiCl₂, AgNO₃ oraniline were used to deposit Ni, Ag, and polyaniline, respectively, overthe nanoparticle. The solution was stirred after each 1 to 2 minutes.The time period of deposition can be optimized with SEM and conductivitymeasurements of the deposited particle.

The synthesized hybrid nanomaterials (PANI/Ni, MoS₂/Ni/PANI, GO/Ni/PANI.MoS₂/Ag, GO/Ag) were characterized using scanning electron microscopy,X-ray diffraction and energy-dispersive (ED) analysis. The conductivitymeasurement was studied using the two probe method.

Preparation of hybrid material based conducting paste: A conductingpaste was formed by mixing amino phenyl epoxy, dicyandiamide, and binderwith one of PANI/Ni, MoS₂/Ni/PANI, and GO/Ni/PANI. MoS₂/Ag, GO/Ag. Thebinder (vinyl acetate—55 to 70% on monomer basis and ethylenemonomers—25 to 40% on monomer basis) was adjusted by measuring theviscosity. The samples prepared for thermal conductivity was cured at150° C. to remove any solvent. Four point probes were used to measurethe conductivity value of the sample using the composition of binder.SEM and FTIR measurements were made to understand the surface andinfrared properties of the paste materials.

Preparation of test sample, coupon and characterization: Adhesion testsmeasurement were made by coating the sample on Al₂O₃ substrates. Thesurface morphology of the film was measured by SEM technique. However,TEM measurement was used to understand the effect of nanomaterial size,its coating as well as dispersion of the material in the paste on theconductivity of the sample.

Corrosion test: Corrosion tests were conducted to characterize thesynthesized paste. The paste was coated over a Cu plate by spray coatingand the paste was annealed at about 150° C. so that in case of GO theCu—O bond could be formed which will act as a passivation layer and willwork as corrosion inhibitory coating material. The coated sample wasstudied using cyclic voltammetry and electrochemical impedancespectroscopy (EIS) methods over a period of time while staying in a saltsolution. To accelerate the test and obtain results similar to long termtests, a biasing voltage was applied to the sample. The Tafel equationand impedance properties were made over the sample for corrosionproperties. After the characterization, the data was analyzed to findthe corrosion rate, charge transfer rate, and stability. The impedanceresults were modeled to find the circuit equivalent model of theelectrochemical interface between the paste layer and the electrolyte.The values of the components in the model give more detail on propertiesof the paste for optimizing the composite material. After, the harshcorrosion tests the morphology of the samples were studied usingscanning electron microscopy.

In depth conductivity before and after the soak test on samples wereperformed. The corrosion test was performed initially at salt-fogexposures. The compatibility test of the coated film with substratesalong with theoretical model was studied.

Other advantages which are obvious and which are inherent to theinvention will be evident to one skilled in the art. It will beunderstood that certain features and sub-combinations are of utility andmay be employed without reference to other features andsub-combinations. This is contemplated by and is within the scope of theclaims. Since many possible embodiments may be made of the inventionwithout departing from the scope thereof, it is to be understood thatall matter herein set forth or shown in the accompanying drawings is tobe interpreted as illustrative and not in a limiting sense.

What is claimed is: 1.-28. (canceled)
 29. A particle comprising ananoparticle core selected from a graphene-containing material, adichalcogenide material, or a combination thereof and a shell at leastpartially surrounding the core, wherein the shell comprises a conductingpolymer.
 30. The particle of claim 29, wherein the nanoparticle corematerial is functionalized with a polyanion.
 31. The particle of claim30, wherein the polyanion is a salt of polystyrene sulfonate.
 32. Theparticle of claim 29, wherein the nanoparticle core is selected from agraphene-containing material or a dichalcogenide material.
 33. Theparticle of claim 29, wherein the graphene-containing material isselected from graphene, graphene oxide, carbon nanoparticle, or acombination thereof.
 34. The particle of claim 29, wherein the corecomprises the dichalcogenide material selected from molybdenumdisulphide, molybdenum diselenide, molybdenum ditelluride, tungstendisulphide, tungsten diselenide, tungsten ditelluride, titaniumdiselenide, titanium disulphide, titanium ditelluride, zirconiumdisulphide, zirconium diselenide, zirconium ditelluride, tin disulphide,tin diselenide, tantalum disulphide, tantalum diselenide, vanadiumtantalum ditelluride, or a combination thereof.
 35. The particle ofclaim 29, wherein the particle comprises the conducting polymer selectedfrom polyaniline, polypyrrole, polythiophene,polyethylenedioxythiophene, poly(ortho-anisidine), poly(methyl aniline),poly(o-ethoxyaniline), poly (o-toluidine), poly (ethoxy-aniline),substituted polyaniline, substituted polypyrrole, polyindole,polycarbazole, substituted polycarbazole, polyaniline-polypyrrolecopolymers, polyaniline-polythiophene copolymers, blends thereof, orcopolymers thereof.
 36. The particle of claim 29, wherein the particleshave an average particle size of 50 nm to 10 microns.
 37. A compositioncomprising the particle of claim
 29. 38. The composition according toclaim 37, wherein the particle is present in an amount of 50-90 wt % ofthe composition.
 39. The composition of claim 38, further comprising adispersant, an adhesive material, or a combination thereof.
 40. Thecomposition of claim 39, wherein the adhesive material includes an epoxyresin, a vinyl ester resin, a polystyrene resin, an acrylic resin, apolyamide resin, a polyamide-amine resin, a carboxyl group-containingresin, or a combination thereof.
 41. The composition according to claim39, wherein the adhesive is present in an amount of 10-50 wt % of thecomposition.
 42. The composition of claim 39, wherein the composition isa conductive paste.
 43. The composition of claim 39, wherein thecomposition exhibits an electrical resistivity of at least 1×10−5ohm·cm, a thermal conductivity of at least 8 W/mK, and chemicalstability at room temperature.
 44. A method of making a particlecomprising: disposing a nanoparticle in a polyanion such that ananoparticle surface becomes functionalized; and polymerizing aconductive polymer over the surface of the functionalized nanoparticle;wherein the nanoparticle is selected from a graphene-containingmaterial, a dichalcogenide material, a conducting polymer, or acombination thereof, and wherein the conducting polymer forms a shell atleast partially surrounding a core comprising the nanoparticle such thatcore comprises 20-80 wt % of the particle and/or shell comprises 20-80wt % of the particle.
 45. The method of claim 44, wherein the polyanionis a salt of polystyrene sulfonate.